1.introduction 2.process and features of fsj 4. actual

2014/9/4

1

Refill Friction Spot Joining

Hideki OkadaKawasaki Heavy Industries, Ltd., Japan

© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 2

INDEX

1.Introduction

2.Process and features of FSJ

3.Evaluation of Joint properties

4. Actual prototype trial

5.Conclusion

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1.Introduction

About us, Kawasaki Heavy Industries,LTD.


1.Introduction

FSJ in Automotive industry

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1.Introduction

Rivet

FSJ attracts attention in Aerospace Industry to replace riveting technology.

ＦＳＪ

Competitive edge in techniques

Competitive edge in costs

Competitive edge in geoenvironmental impact and working environment

High flexibility in designing (e.g. FSJ spacing can be closer together) Lighter weight than rivets

Low electric consumptionVery little noise and vibration.

High productivity of FSJ leads to cost reduction.( No need to preprocessing such as drilling, deburring)Reduction in materials cost (elimination of rivets)

What is the future of aviation fastening


Retained water generated bycondensation in exit-hole can lead tocorrosion

Thin section and flash will be a fatiguebreak point

Optimized tool length is required foreach plate thickness

Exit-hole

Flash

Hook

Thin section

Basic FSJ process and disadvantages for Aircraft

1.Introduction

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2.Process and features of Refill FSJ

(2)Plunge

Plunging

Stir zone

Holding

Work

Clamp

Holding

Shoulder

Probe

(3)Re-plunge(1)Clamping and pre-heating (4)Tool removal

Work

Clamp

Holding

Shoulder

Probe

(3)Re-plunge(1)Clamping and pre-heating (4)Tool removal

Probe-Plunging

Refill FSJ process and advantages

PlungingHolding

(2)Plunge

Shoulder-Plunging



PlungingHolding

Probe-PlungingRefill FSJ process and advantages

Clamping tool encloses the shoulder tool holdswork-piece tightly to prevent burring and creates a flat surface.

Probe Plunging process looks like basic FSJ.Shoulder plunging process has excellent tensile strength

In either case, refill process can make surface flat.

Plunging

Holding

Shoulder-Plunging

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Cut model animation of shoulder plunging process



3 servo motors in refill FSJ gun providestools rotation, shoulder and probe motions independently.

Refill FSJ gun has high Z force (up to 14.7kN) and can joinup to t4mm(Upper-sheet) of aluminum alloy and some other materials.

Refill FSJ system developed by KHI

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Top side surface Back side surface Joint surface is almost flat No dent on top/back surfaceJoining time is 3.7s

Joint appearance of Al2024C-T3 Alodine #1200 coated

Material Thickness SpecificationUpper sheet Al2024C-T3 .040 inch(1.02mm) AMS-QQ-A-250/5Lower sheet Al2024C-T3 .040 inch(1.02mm) AMS-QQ-A-250/5



Number 30Min. [N] 2702Max. [N] 3117

Average[N] 2960S.D [N] 113

C.V. [％] 3.82A value [N] 2614

122813741/8' Rivet joint [N] 　（MMPDS）

RSW joint [N] 　（MMPDS）

RefillFSJ joint

Result of tensile shear test

Tensile shear fracture modealmost specimens showed pull out fracture

Tensile shear test of Al2024C-T3 Alodine #1200 coated

0.040int 0.040int

C.V. (Coefficient of Variation) = S.D. / Average *100

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Evaluation of Edge DistanceED ED [mm] 6 8 10 12.5

Number 10 10 10 10Min [N] 2416 2739 2783 2919Max [N] 2879 2985 3095 3007

Average [N] 2636 2877 2966 2954

0

1000

2000

3000

4000

6 8 10 12.5

ED [mm]

Shea

r str

engt

h [N

]




Evaluation of Joint pitch

Pitch [mm]

Shea

r str

engt

h [N

]

0

2000

4000

6000

8000

10000

10 20 24

Pitch [mm] 10 20 24Number 10 10 10Min [N] 6997 8078 8461Max [N] 7666 8712 8911

Average [N] 7391 8520 8636

Pitch

72mm


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Number of Cycles

Par

cent

of s

tatic

stre

ngth

of j

oint

(%)

0.040”/0.020”0.040”/0.025”0.040”/0.032”0.040”/0.040”Spot Welding Joint (MMPDS)

125

25

25

12.5

Joint lap fatigue test of Al2024C-T3 Alodine #1200 coated

Thickness[inch]

0.020/0.040

0.025/0.040

0.032/0.040

0.040/0.040

Rifill FSJ [N](Average) 2277 2281 2249 2960

RSW [N](MMPDS) 498 658 925 1228



Clad material

Disappearance of interface

Φ6.11mm ＝ SZ

Cross section of Al2024C-T3 Alodine #1200 coated

Al Cu

Cr O

Upper sheetAl2024C-T3

Lower sheetAl2024C-T3

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(1)Clamping and pre-heating (4)Tool removal(3)Re-plunge(2)Plunge

EPMA analysis of Al2024C-T3 Alodine #1200 coated

Cr disappeared

Cr Cr



Exposure time：168Hr

Al2024-T30.020”

Salt spray

Al6061-T60.025”

Apply Sealant before FSJ

Outside surface

Interfacial surface

Outside surface: UncorrodedInterfacial surface: CorrodedOutside surface: UncorrodedInterfacial surface: Uncorroded

Corrosion test of Al2024C-T3 Alodine #1200 coated

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Cross section and Tensile shear test of Al6061/Al2024C with sealant With

SealantWithoutSealant

Number 15 3Min [N] 2070 2229Max [N] 2383 2352

Average [N] 2211 2297

To improve corrosion resistance, joint within Sealant

A6061-T6

A2024C-T3

With sealant(Unetched)

A6061-T6

A2024C-T3

Without sealant(Etched)



Dissimilar joint of Aluminum and steel for Automobile

Ti-6Al-4V (1mm + 1mm)

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1.Pilot door

Parts Name Thickness[mm] Material Parts Name Thickness[mm] MaterialINNER SKIN 0.635 6061-T62 DOUBLER 0.635 2024C-T3OUTER SKIN 0.635 6061-T62 DOUBLER 0.635 2024C-T3

DOUBLER 0.8128 2024C-T42 CHAMMEL 0.635 6061-T62ANGLE 0.635 2024C-T42 DOUBLER 0.635 6061-T62SPLICE 0.635 2024C-T42 DOUBLER 0.635 2024C-T42

DOUBLER 0.635 2024C-T42



Fixture of this trial

1.Pilot door

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Joined small parts of this trial

1.Pilot door



Appearance of joined Inner/Outer SKIN

1.Pilot door

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1.Pilot door



with Alodine#1200

2.Frame component

ConbinationRefill FSJ

Joint lap shear strength(N)WEB-DOUBLER 2322WEB-CAP 2121

WEB-DOUBLER-CAP 3977

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2.Frame component



With AnodizeFaying sealant at the interface

3.Skin panel

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3.Skin panel (Close-up picture)



3.Skin panel (actual movie)

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5.Conclusion

Refill FSJ joint has a smooth surface without defect, flash and exit hole.

Joint lap shear strength is impressive in comparison to RSW and riveting.Even though Alodine, Chromic Acid Anodize material, and with faying sealant material.

Newly developed refill FSJ robot system can join aircraft trial parts successfully with minimal distortion.

This technology has a potential to produce parts at a high rate with high quality.


Thank you for your kind attention

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1.introduction 2.process and features of fsj 4. actual

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